Roofing Element with Placement Indicator Features, Roof Comprised Thereof and Method of Applying the Elements to a Roof

ABSTRACT

A synthetic roofing element is provided having laterally spaced-apart placement indicators in a headlap portion thereof, defining a spacing zone between the placement indicators, with the placement indicators comprising a means for providing a visual indication of proper placement of spaced-apart edges of adjacent roofing elements in a next-overlying course of roofing element. The placement indicators can comprise vertical lines, and can include instructions in text. Spacing nibs can also be used. The placement indicators can include markings for placing corners of tabs of next-overlying roofing elements. A roof comprised of such roofing elements and a method of applying such elements are also disclosed.

BACKGROUND OF THE INVENTION

In the manufacture of asphalt based roofing products, particularly products of the shingle type, the shingles are generally of a width of, for example, 36 inches, and 18 inches high, with there generally being a plurality of tabs, such as for example, 3 or 4 tabs extending between left and right edges of the length of the shingle, such that the shingles, each being fairly large, nevertheless simulate individual slate or tile shingles when laid up on a roof, such that the substantially large size of the shingles facilitates, by itself, alignment of adjacent shingles in a given course, and alignment of subsequent courses of shingles laid thereover.

Additionally, in prior art types of shingling of roofs with asphalt based roofing products, it is known to provide a single line, notched into the shingle, to be used as an alignment reference, with the line generally running between right and left edges of the multi-tab shingle.

THE PRESENT INVENTION

The present invention is directed to a synthetic roofing shingle or tile, manufactured to simulate a single natural slate shingle or tile, such as a cedar shake shingle, a slate shingle or tile, or the like. Such synthetic shingle elements may be molded or otherwise manufactured of synthetic materials, and will generally have greater thickness than asphalt based roofing products, but will more often have greater weight and therefore will generally be of single tab width between right and left edges. Thus, such synthetic roofing elements are generally smaller in width between side edges than asphalt based roofing products and will generally require a larger number of such roofing elements to cover a roof of a given size than with asphalt based roofing products. With a greater number of roofing elements being required, proper alignment of the roofing elements as they are applied is increasingly important to yield a desirable aesthetic appearance when the shingles are installed on a roof.

SUMMARY OF THE INVENTION

The present invention is directed to providing a synthetic roofing element that is adapted to be laid up in courses on a roof, with visual alignment placement indicators disposed in the headlap portion of the roofing element for providing a visible indication of proper placement of spaced apart edges of adjacent roofing elements in a next-overlying course of roofing elements, relative to the roofing elements in an underlying course.

The present invention is also directed to a roof comprised of such roofing elements, and a method of applying such elements to a roof.

BRIEF DESCRIPTIONS OF THE DRAWING FIGURES

FIG. 1 is a top plan view of a fragmentally illustrated portion of a roof, with a plurality of synthetic roofing elements of an underlying course being illustrated, and with a roofing element of a next-overlying course being illustrated, with a plurality of types of laterally spaced-apart placement indicators visually disposed in the headlap portions of the roofing elements, and with indicia legends shown on the upper ends of headlap portions of the roofing elements, on top surfaces thereof.

FIG. 2 is an enlarged indicia legend of the type shown at II in FIG. 1, wherein the alignment instructions thereof are illustrated in greater detail.

FIG. 3 is a fragmentary portion of an alternative embodiment of a roofing element to that shown in FIG. 1, but wherein placement indicators in the form of a means for guiding the placement of next-overlying roofing elements are shown for the placement of alternative, seemingly random positions of overlap of overlying roofing elements relative to the underlying roofing elements.

DETAILED DESCRIPTIONS OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in detail, reference is first made to FIG. 1, in which a roof generally designated by the numeral 10 is fragmentally illustrated. The roof 10 will generally be sloped for the purpose of shedding water, snow, etc. therefrom. The roof 10 shown in FIG. 1 may or may not have a layer of roofing underlayment, such as tarpaper or the like thereon, over which roofing elements in accordance with this invention are applied.

In the fragmental illustration of FIG. 1, it will be seen that portions of a first or underlying course of roofing elements are shown as elements 11, 12, 13 and 14, and a roofing element 15 of an overlying course of roofing elements is shown, disposed with its lower tab portion 16 overlying parts of headlap portions 17 of roofing elements 12 and 13.

The roofing elements 11-15 will generally be of substantially identical, or at least similar construction, and will essentially comprise synthetic shingles or tiles, that may be based on polymeric materials and can be comprised of multiple layers of different materials, as may be desired. Preferred polymeric materials are thermoplastic materials, but thermoset materials could also be used. In some such elements, recycled polymer content may be employed. Examples of suitable polymeric materials would include, but not be limited to, polyethylene material, a polypropylene, a polymethylpentene, a polybutene, a polyacrylate, a polyvinylchloride, a polyester or blends of various synthetic polymers, all as may be desired. Such synthetic shingles or tiles could also be comprised of ceramic materials or fiber cement materials (i.e., cement-like materials having fibers therein). Such roofing elements are preferably constructed of a thermoplastic resin material which may or may not have fillers therein, and which may or may not have reinforcement materials therein, such as lengths of fiber, for additional strength. The roofing elements will also preferably be molded or shaped to simulate natural slate, tile or shake materials. The roofing elements have front surfaces 18 that define lower tab portions 16 and upper headlap portions 17.

The roofing elements also have rear surfaces (not shown) that may, if desired, be partially or substantially hollowed-out, and may or may not contain supporting ribs (not shown).

The roofing elements may, if desired, have separate materials for their core and capstock (outer, weather-exposed portions, if desired).

The roofing elements 11-15, being similar in construction, the further details thereof will be described with reference to roofing element 15, although it will be understood that similar features apply to roofing elements 11-14 and other roofing elements in the various courses that make up a roofing-element-covered roof.

The roofing element 15 is representative of a roofing element of an overlying course to the roofing elements 11-14 of the first course, or underlying course, illustrated in FIG. 1.

The headlap portion 17 of roofing element 15 has right and left side edges 20 and 21 that are wider from left to right in the headlap portion 17, than in the tab portion 16, because of the cut-back or notched portions 20′ 21′ of the edges 20, 21, to make the tab portion 16 of the roofing element 15 narrower from left to right than the headlap portion 17, to accommodate the formation of slots such as those 22, 23, between roofing elements 13, 14 and 12, 13, illustrated in FIG. 1.

Each of the roofing elements, such as the element 15, will preferably have spacing nibs 24, 25 protruding from the right side of the edge 20, and spacing nibs 26, 27, protruding from the left edge 21 of the headlap portion of the roofing element, as shown.

With reference to the space between adjacent roofing elements 13 and 14, it will be seen that the spacing nibs 24-27, are in pairs, vertically offset from one roofing element 13 relative to an adjacent roofing element 14, to facilitate a desired spacing therebetween. All of the nibs 24-27 are preferably comprised as protrusions from their respective side edges of the roofing elements, being molded or otherwise formed integrally therewith.

A plurality of placement indicators are provided for the roofing elements of this invention. Such placement indicators may take the form of a plurality of pairs of generally vertical lines 29, 30, 31, 32, with each pair 29, 30 and 31, 32 being spaced vertically from each other, and with the lines within each pair, such as those 29, 30 and those 31, 32, spaced laterally from each other, as shown. Such placement indicators 29-32 provide a visual indication for proper placement of spaced-apart edges 20, 21 of next-overlying roofing elements to be disposed thereagainst.

Assisting such placement indicators, are arrows 33, 34, 35 and 36, or any other indicia, pointing the installer of roofing elements to the laterally spaced apart vertical lines 29, 30, 31, and 32, respectively, against which to place edges 20, 21 of next-overlying roofing elements. It will be noted that the laterally spaced apart vertically disposed lines or placement indicators 29, 30 and 31, 32 are disposed substantially midway between the edges 20 and 21 in the headlap portion 17 of the roofing element 15, in the embodiment thereof shown in FIG. 1, so that the placement of vertical edges of next-overlying roofing elements in a next-overlying course, can be spaced apart a desired amount to leave an appropriate horizontal spacing, such as is shown at 22, 23 between roofing elements 13, 14 and 12, 13 in FIG. 1. In lieu of the vertical placement indicators, 29, 30, 31, 32, other indicia may alternatively be utilized, as may other indicia be utilized in lieu of the arrows 33, 34, 35 and 36.

Placement indicators 37, 38 may be provided protruding upwardly from an upper edge 40 of the roofing element 15, to alternatively indicate a proper placement of side edges 20, 21 of a next-overlying pair of roofing elements, and such may be used in addition to, or instead of the placement indicators 30, 31, 32, 33. These placement indicators 37, 38, can likewise be formed as nibs, integral with the structure of the roofing element 15, as may be desired.

The nibs 37, 38, may also be used as a placement or alignment indicator, when other guidelines, such as chalk lines 42 are used on a roof, such that the roofing elements may be located relative to the guidelines or chalk lines 42 by locating the roofing elements that carry the nibs, 37, 38, such that the nibs 37, 38 are equally spaced on each side of a guideline or chalk line 42, as shown in FIG. 1.

An indicia legend 43 is provided at the upper end of the headlap portion 17 of the roofing element 15, which indicia legend is shown in enlarged form in FIG. 2. The indicia legend 43 in FIG. 1 includes instruction portions 50, 51 on each side of the vertical lines 29, 30. Those instruction portions 50, 51, are too small to depict the actual instructions in the illustrations of FIG. 1, but are sufficiently large in FIG. 2 to be legible, such that the instruction portion 50 in FIG. 2 reads L←R Align Left Side Here. In FIG. 2, the instruction portion 51 reads Align Right Side Here L→R. These instructions provide direction to an installer of roofing elements, how to align a right or left edge of a next-overlying roofing element, relative to the vertical lines 29, 30, 31, and 32.

With reference to FIG. 1, it will also be seen that along the right edge 20 of the roofing element, there appear three short horizontal lines 45, 46 and 47, with respective markings 6, 7 and 8 alongside, and that along the left side 21 of the roofing element there likewise appear three short horizontal lines 53, 54 and 55 likewise with numbers 6, 7 and 8 respectively indicated alongside such lines. In the case of the desire to have an 8 inch exposure of a tab portion 16 of an underlying shingle, one would align the horizontal lines 47, 55 of a next overlying roofing element 15, with upper edges 40 of next-underlying roofing elements 12, or 13. Likewise, if one wanted to have a 7 inch exposure or a 6 inch exposure, one would align the upper edges 40 of next-underlying roofing elements with the short horizontal lines 46, 54 for a 7 inch exposure of tab portions of next-underlying roofing elements, and for a desired 6 inch exposure of tab portions of underlying elements, the upper edges 40 of underlying roofing elements 13, 12, would be aligned with the short horizontal lines 45, 53. Thus, the present invention provides for some variation in determining the desired tab portion exposure of courses of shingles as they are laid up on a roof 10.

Additional placement indicators are also provided in the form of right and left facing “L” type indicators 60, 61, having vertical and horizontal legs, as shown, with their vertical legs being spaced apart the desired spacing apart of lower ends of tab portions of opposing corners of next-overlying roofing elements in a course thereagainst. These indicators 60, and 61, are shown with adjacent numerals “8” nearby, indicating the placements of lower edges 41 of adjacent spaced-apart tab portions of adjacent roofing elements thereagainst where an 8 inch exposure is desired for the tab portions of next-underlying roofing elements relative thereto.

With reference now to FIG. 3, it will be seen that, as distinguished from the placement indicators 60, 61, which are substantially centrally located between edges 20 and 21 of the roofing element illustrated in FIG. 1, in FIG. 3, other pairs of placement indicators 62, 63 are shown representing a 4 inch displacement of the spacing of a next-overlying adjacent edge of an adjacent shingle element relative to left edge 68 of roofing element 70, or a 5 inch displacement as indicated by the placement indicators 64, 65, or a 6 inch displacement from edge 68 as indicated by the placement indicators 66, 67, all for a roofing element 70 having a 12 inch width between opposite edges 68, 71, as shown. Thus, the placement indicators illustrated in FIG. 3 in each case comprise a pair of markings on the upper surface of the roofing element, at the lower end of the headlap portion of the roofing element, wherein the markings comprise visual indicator means for placing corners of tab portions of adjacent roofing elements in a next-overlying course of roofing elements so that the markings are disposed at locations other than midway between right and left edges of the roofing element, to provide means for guiding the placement of next-overlying roofing elements at seemingly random positions of overlap to the underlying roofing element, as distinguished from the seemingly uniform positions of placement of next-overlying roofing elements over a next-underlying roofing element, such as is indicated by the position indicators 60, 61, in FIG. 1. However, it is desirable to always have two to three inches of a roofing element as shown in FIG. 3, and markings such as 62, 63, spaced from edges 68, 71, so that under weather conditions such as water, snow or the like, moisture cannot readily pass from a slot between adjacent tabs of adjacent elements in an overlying courses through a slot formed between tabs of adjacent elements in a next-underlying course. That is, slots between adjacent tabs of elements in any given course should not be aligned with, or even close to being aligned with, a slot in a next-underlying course. This is especially important when there are roofing elements of multiple widths in any given course. It will further be noted that by using guides, such as those 62, 63, 64, 65, 66, 67, especially with numbers adjacent thereto, such as the numbers 4, 5 and 6, such also functions as a warning to the installer, not to place a side edge of a next-overlying roofing element too close to an edge such as that 68 or 71 of a next-underlying roofing element.

Accordingly, it will be seen that, in accordance with this invention variations of placement of next-overlying roofing elements, leftward and rightward is possible, to accommodate the selection of different dimensions of offsets leftward and rightward of next-overlying roofing elements in a course, as well as to allow for vertical alignment of such roofing elements in a next-overlying course.

In FIGS. 1 and 3, it will be seen that nailing zones 75 and 76 are provided, each to accommodate nails or other fasteners 77, 78, for securing the roofing elements to a roof.

In accordance with this invention, it will therefore be seen that these visual alignment indicators assist the installer, in terms of providing efficiency of time and effort, by providing ready reference for the application of roofing elements. Such visual alignment indicators also help prevent incorrect application in that roofing elements are indicated to be applied for correct positioning.

It will also be apparent that the parallel lines or opposing parallel lines or groupings of lines allow for variable spacing. These lines are positioned such that they, in the case of the embodiments of FIG. 1, are slightly off center from the precise central portion of the roofing elements between edges 20 and 21, in order to accommodate thermal expansion/contraction and avoid buckling of adjacent pieces due to thermal considerations. Also, it will be apparent from the embodiment of FIG. 1 that the spacing between adjacent roofing elements may be accommodated by use of laterally protruding nibs 24-27 as may be desired.

Once an applied roofing element is positioned and multiple roofing elements are applied in a course, the roofing elements applied in a subsequent course can be aligned correctly, with exposure previously determined and aided by use of an exposure mark, by placing a side of the roofing element directly to and over an alignment line, covering its visual location, with the alignment accomplished. It will also be apparent that the alignment features addressed herein for roofing elements are obscured from view once the roofing elements are installed. This is principally because all of the alignment features are located in the headlap portions of the roofing elements, as will be apparent from the drawings.

Also, by using two sets of spaced apart vertical lines, one below the other, as indicated by the lines 29, 30, 31, 32, such allows for alignment both vertically and horizontally by helping to prevent twisting or inadvertent angular orientation of the roofing elements. The alignment lines as indicated at 29, 30, 31 and 32 also allow the arrow indicators 35-38 or other geometric shapes to further focus attention of the installer to the desired alignment positioning as indicated in FIG. 2, and the addition of text can reinforce the desired alignment parameters.

Additionally, the two opposing and spaced parallel lines 29-32 can accommodate applying roofing elements around dormers, unusual roof design considerations, or simply right or left-handed installers.

Also, in accordance with this invention multiple horizontal locations for alignment indicators are provided on the same roofing element for the possibility of custom design application, for facilitating various offsets, as described above. Thus, the present invention provides considerable flexibility for meeting various installation requirements and/or patterns.

The placement indicators may be embossed in the upper surfaces 18 of the roofing elements, or raised therefrom in relation to the roofing element. Alternatively, such indicators can be printed on or attached in the form of a laminated continuous or discontinuous film or other medium, including but not limited to an adhered sticker, a differentiated color reference, a metallic attachment, implant or pin of dissimilar material on the top surfaces 18 of the roofing elements.

It will be understood that, as used throughout this specification, the words “shingle”, and “tile” are used interchangeably, and in some cases are referred to as “slate”, or “synthetic slate”, or “synthetic shake”, all intended to be without limitation. Also, as used throughout herein, the term “nailing zone” is intended to apply in the broadest sense, to include any type of fastening zone, whether it be for a nail, staple, screw, rivet or the like. Because roofing products have conventionally been applied via nails, the zones of the shingles or tiles through which fasteners are applied have conventionally become referred to as “nail zones”, although it will be understood that any type of suitable fastener may be used, and will fall within the scope of “nail zone” or “nailing zone” as used herein.

Various modifications may be made in the details of construction, as well as in the installation and method of installation of roofing elements in accordance with this invention, all within the spirit and scope of the invention as defined in the appended claims. 

1. A synthetic roofing element of the shingle or tile type, adapted to be laid up in courses on a roof, having an upper headlap portion and a lower tab portion; (a) the roofing element having vertically spaced apart upper and lower edges, laterally spaced apart right and left edges and top and bottom surfaces; (b) with the bottom surface adapted to be laid up on a roof facing the roof; (c) with the top surface having its tab portion adapted to be substantially weather-exposed when laid up on a roof and with its headlap portion adapted to be substantially covered by roofing elements in a next-overlying course of roofing elements when laid up on a roof; (d) with a pair of laterally spaced apart placement indicators disposed in the headlap portion of the roofing element, defining a central spacing zone between said placement indicators, which spacing zone is substantially midway between the right and left edges of the roofing element; (e) with the placement indicators comprising means for providing a visual indication of proper placement of spaced apart edges of adjacent roofing elements in a next-overlying course of roofing elements.
 2. The roofing element of claim 1, wherein the placement indicators comprises a pair of generally vertical lines.
 3. The roofing element of claim 2, wherein the placement indicators comprise two pairs of generally vertical lines, with each pair of lines being generally vertically aligned and vertically spaced apart.
 4. The roofing element of claim 2, wherein the placement indicators comprise a pair of spaced apart nibs protruding from the upper edge of the roofing element.
 5. The roofing element of claim 2, wherein the placement indicators comprise a pair of markings on the upper surface of the roofing element on the lower end of the headlap portion of the roofing element.
 6. The roofing element of claim 5, wherein the markings comprise visual indicator means for placing corners of tab portions of adjacent roofing elements in a next-overlying course of roofing elements.
 7. The roofing element of claim 5, wherein the markings include a numeric indicator of the height of exposed tab portion for tabs of roofing elements in a next-underlying course.
 8. The roofing element of claim 6, wherein the markings are disposed generally midway between right and left edges of the roofing element, to provide means for guiding the placement of next-overlying roofing elements at seemingly uniform positions of overlap to the underlying roofing element.
 9. A synthetic roofing element of the shingle or tile type, adapted to be laid up in courses on a roof, having an upper headlap portion and a lower tab portion; (a) the roofing element having vertically spaced apart upper and lower edges, laterally spaced apart right and left edges and top and bottom surfaces; (b) with the bottom surface adapted to be laid up on a roof facing the roof; (c) with the top surface having its tab portion adapted to be substantially weather-exposed when laid up on a roof and with its headlap portion adapted to be substantially covered by roofing elements in a next-overlying course of roofing elements when laid up on a roof; (d) with a pair of laterally spaced apart placement indicators disposed in the headlap portion of the roofing element, defining a spacing zone between said placement indicators, which spacing zone is between the right and left edges of the roofing element; (e) with the placement indicators comprising means for providing a visual indication of proper placement of spaced apart edges of adjacent roofing elements in a next-overlying course of roofing elements. (f) wherein the placement indicators comprise a pair of markings on the upper surface of the roofing element on the lower end of the headlap portion of the roofing element; wherein the markings comprise visual indicator means for placing corners of tab portions of adjacent roofing elements in a next-overlying course of roofing elements; wherein the markings are disposed at locations other than midway between right and left edges of the roofing element, to provide means for guiding the placement of next-overlying roofing elements at seemingly random positions of overlap to the underlying roofing element.
 10. The roofing element of claim 2, wherein a plurality of said roofing elements are disposed on a roof, and wherein a plurality of vertical guidelines are disposed on the roof, and with the pair of placement indicators being substantially evenly located on each side of the guidelines.
 11. A roofing element in accordance with any one of claims 1-2, including an indicia legend in the headlap portion of the element; said indicia legend including alignment instructions for an installer of roofing elements; with said alignment instructions including instructions about placement of edges of next-overlying shingle elements relative to said placement indicators.
 12. A roof comprising a plurality of roofing elements in accordance with any one of claims 1-2 and 9, applied to a roof in a plurality of courses; with a plurality of roofing elements disposed side-by-side in each course.
 13. A method of applying roofing elements of any one of claims 1, 2 and 9 to a roof comprising the steps of: (a) applying a first course of roofing elements to the roof, with adjacent said elements in a course being laid side-by-side; then (b) applying a second course of roofing elements to the roof, with each element in the second course being applied with one of its right and left edges aligned against one of the laterally spaced-apart placement indicators of a pair of placement indicators in the headlap portion of a next-underlying roofing element of the first course of roofing elements.
 14. A roofing element in accordance with any one of claims 1 and 9, wherein the placement indicators are obscured from view in the installed condition of roofing elements on a roof.
 15. A roof in accordance with claim 12, wherein the placement indicators are obscured from view in the installed condition of the roofing elements on a roof. 